Training and Further Education
in Automotive Engineering
Know-how – Skills – Passion
Training in the Automotive Diagnostics
Workshop Lab
3rd Edition
Contents
Know-how – Skills – Passion
Training Systems for Automotive Engineering ................................................................................................................................... 4
More Than a Laboratory
Complete Solution – Diagnostics Workshop Lab for Automotive Engineering ................................................................................... 6
System Overview
Needs-oriented Training Systems ...................................................................................................................................................... 8
Multimedia Learning Environment
LabSoft as a System-based Training/Administration Software .......................................................................................................... 14
The Entire Program at a Glance
Solutions for Vocational Training and Education in Automotive Engineering ................................................................................... 16
Contents
Electricity/Electronics ............................................................................................................................................................. 20-27
DC and AC Technology in the Motor Vehicle, Automotive Electronics and Digital Technology, Three-phase (Alternator)
Generator, Pulse-width Modulated Signals (PWM), Three-phase Generator with Multifunction Controller, Three-phase
Generator with Hybrid Controller
Sensors and Actuators ........................................................................................................................................................... 28-33
Sensors and Actuators in the Motor Vehicle, Engine Management Sensors
Motor Vehicle Lighting .......................................................................................................................................................... 34-43
Main Lighting and Signalling Systems, Trailer Lighting, Static Cornering Lightings, CAN Bus Extension,
Onboard Power Supply Extension
Comfort Systems .................................................................................................................................................................... 44-51
Alarm System and Immobilizer, GPS Navigation, Air-conditioning and Climate Control, Auto Shop Communications with RFID,
Comfort Systems and Keyless Entry
Alternative Drives .................................................................................................................................................................. 52-61
CarTrain E-mobility, Hybrid Drive in Motor Vehicles, DC/AC Conversion, Fuel Cells, Photovoltaic Technology
Engine Management ............................................................................................................................................................. 62-83
CarTrain Motronics 2.8, CarTrain Direct Fuel Injection, CarTrain Common Rail, Student/Teacher Measurement Stations,
Function Motors and Cutaway Models, Ignition Systems, Diesel Injection System Common Rail, Common Rail,
Electronic Diesel Control (EDC), Connect®-Fire Chip Tuning, Auto-diagnostics Trainer Software
Vehicle Diagnostics ............................................................................................................................................................... 84-91
Onboard-Diagnosis II, CAN/LIN Monitor, High-voltage Instrumentation, Snap-on MODIS, Snap-on SOLUS PRO, Snap-on VERUS
Chassis and Driving Safety ................................................................................................................................................. 92-101
Electromechanical Parking Brake, Electromechanical Power Steering, Airbag, Belt Tensioner and Crash Response,
SRS Airbag and Belt Tensioner, ABS, ASR and ESP, Brake Power Control with ABS and ASR
Networked Systems ........................................................................................................................................................... 102-111
CAN Bus, CAN Lighting Technology, CAN Comfort Technology, LIN Bus, Fiber Optic Waveguides, FlexRay,
Dashboard Training Model Incorporating CAN and LIN Buses
Practical Automotive Workshop Lab ................................................................................................................................ 112-119
Exhaust Gas Analysis and EOBD Data Readout, Tyre-Mounting Machine, Balancing Machine, Axle Measurement,
Two-column Hydraulic Car Lifting Platform, Four-column Hydraulic Car-lifting Platform,
Fully-automatic Air-conditioning Service Unit, Tool Trolley
Topics................................................................................................................................................................................... 120-121
Know-how – Skills – Passion
Training Systems for Automotive Engineering
Rapid developments in the sector ...
... require solid training ...
Technical developments in the automotive industry are so rampant
that even well-trained experts are not always finding it so easy to
keep up on the job. Getting trainees and students up to speed,
cultivating their enthusiasm for new technologies and providing
them with the tool set needed for a successful future career – these
are today’s automotive training challenges for tomorrow. After all,
only well-trained, committed specialists are able to cope with new
challenges and promote innovation.
Rising demands being placed on equipment, cost efficiency, safety optimization, intelligent drive systems and mobile communication in the motor vehicle are making this field exciting and the
dream profession of many young people. At the same time these
developments are putting more and more intense pressure on
industry and the skilled trades. Ultimately, it is only the specialists
who are capable of developing their own strategies and solutions
and able to perform best in a team that will be able to keep up
the momentum driving innovation in the industry. Modern automotive technology instruction that is able to cultivate the next
generation must therefore combine practical and theoretical content in a consistent manner and promote independent learning
while at the same time remain oriented towards the latest technologies.
4
... using premium training systems.
To be able to impart this in a sustained fashion training systems
are needed which are not only state of the art technically but also
didactically conceived to comply with the requirements prevalent
in the workplace. Practical exercises and well-grounded theoretical
background information form the foundation for one of the key
competences: excellent hands-on skills. These skills are already
developed by the trainee during the training period in conjunction
with the Lucas-Nülle training systems. In the course of working
on projects and during self-monitored learning processes, young
people discover the fascination of automotive technology while at
the same time attaining a high degree of work satisfaction. This is
because individual learning and positive feedback are part of the
didactic concept.
Covering everything from the basics to
final graduation
“The training systems from Lucas-Nülle cover every aspect of
training in automotive technology. Whether the subject is the
basics of automotive electricity, lighting and comfort systems
or motor vehicle diagnostics, LN has the corresponding system
for every subject and situation.
All of the training subjects are thoroughly covered in the
Automotive Diagnostics Workshop Lab.
Using modular and scalable learning and training systems
the foundation is laid for an enduring, continuously updated training and educational program at the workplace, in
vocational schools and industry-wide training.”
Siegfried Schulz
Product Manager Automotive Engineering
Martijn Vincken
Product Manager Automotive Engineering
5
More Than a Laboratory
Complete Solution – Diagnostics Workshop Lab
for Automotive Engineering
Lucid presentations of complex concepts with
modern training and educational media
Complete solutions for modern engine
management, brake, climate control and
airbag systems
Training Panel Systems
Individual experiment set-ups for competent system
understanding
CarTrain
Training on real components – interactive course s­ oftware is
used to facilitate overall system comprehension
6
Lucas-Nülle
Student Measurement Stations
Multisignal-capable environment provided for each student
as a guarantee for optimum learning success
Training Vehicle
Diagnostics performed directly on the motor vehicle –
testing and maintaining networked systems
UniTrain-I
Deepening the student’s understanding using
the hardware and software provided with the
experiments
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Lucas-Nülle
System Overview
Needs-oriented Training Systems
UniTrain-I – a Multimedia Laboratory with over 100 Courses
With the UniTrain-I multimedia experiment and training system,
students are guided through the experiments by means of clearly structured course software including texts, graphics, animations and knowledge tests. In addition to the training software,
each course comes with an experiment card for performing
practical exercises. Courses such as those on the fundamentals of electrical engineering, automotive sensors and ignition
systems convey the knowledge and skills needed to understand,
connect, diagnose and operate modern automotive systems.
Animations and numerous experiments on authentic systems
found in the various courses impart the fundamentals, principles
and attributes of electrical, safety, lighting and engine-management equipment.
Your benefits
• Theory and practice all in one
• PC and new media for high levels of student motivation
• Quick success through structured course design
• Animated theory for quick understanding
• Practical competence through independent experimentation
• Guided trouble shooting with an integrated fault simulator
• Protective, extra-low voltages ensure safe operation
• Sample solutions for teachers and students
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Lucas-Nülle
Kraftfahrzeugtechnik
UniTrain-I system
•Comprehensive, portable laboratory
•Multimedia-based courses
•High-tech measurement and control interface
•Trains theory and practice at same time and location
Integrated meters and power supply units
•Multimeter, ammeter, voltmeter
•2-channel storage oscilloscope
•Function and signal generator
•Three-fold power supply unit for AC and DC
•Three-phase power supply unit
•… and many more instruments
LabSoft learning and experimenting software
•Wide selection of courses
•Comprehensive background theory
•Animations
•Interactive experiments with instruction guide
•Free navigation
•Documentation of measurement results
•Tests available in the language of your choice
UniTrain-I interface with USB
•Oscilloscope with 2 analogue differential inputs
•Sampling rate of 40
Msamples/s
•9 measuring ranges from
100 mV - 50 V
•22 time ranges from
1 µs - 10 s
•16 digital inputs/ outputs
•Function generator for
frequencies up to 1 MHz
•8 relays for fault simulation
UniTrain-I experimenter
•Holds experiment cards
•Experiment power supply of
± 15 V, 400 mA
•Experiment power supply of
5 V, 1 A
•Variable direct or threephase current, 0 - 20 V, 1 A
•IrDa interface for multimeters
•Serial interface for additional
experiment cards
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Lucas-Nülle
System Overview
Needs-oriented Training Systems
EloTrain Courses: 2mm Plug-In System
Together with the multimedia experimentation and training system, the EloTrain 2-mm plug-in system provides a modern and
efficient environment for sound training in the fundamentals of
electrical engineering and electronics.
Students are guided through the experiments by means of
clearly structured course software including texts, graphics,
animations and knowledge tests. The experiments are tailored
especially to automotive applications to facilitate an understanding of this complex subject and are conducted on a 2-mm experimenter developed specially for the UniTrain-I. A wide range
of virtual instruments are available for real-time measurements
by students.
Multimedia course with measure interface
Your benefits
• Modern educational media combined with a proven system of plug-in modules
• Virtual instruments for real-time measurements of current, voltage and resistance; no need for external power supplies or
measuring instruments
• High student motivation through new, PC-based media
• Quick success through structured courses
• Practical competence through independent experimentation
• Regular feedback through quizzes and knowledge tests
• Safe handling thanks to protective, extra-low voltages
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Lucas-Nülle
Kraftfahrzeugtechnik
EloTrain Courses: 4mm Plug-In System
The EloTrain 4-mm plug-in system is an extensive kit for experimentation in the field of electrical engineering, electronics and
digital technology. By installing 4-mm plug-in modules on an
EloTrain experimenter, electronic circuits of any required size
can be assembled, operated and tested. Students are guided
through the experiments by means of clearly organized experimentation instructions; the knowledge acquired in this process is
consolidated in numerous tests.
This set is especially tailored to the needs of students in the
field of automotive and allows a vast range of experiments
on the fundamentals of automotive electrical engineering and
electronics. The set comes on an A4 storage plate with scratchresistant, colour print.
Training course with comprehensive manuals
Your benefits
• Gold-plated contacts
• Extremely practical approach
• Students’ exercises tailored specially to automotive engineering
• 1:1 mapping of circuit diagrams on the rastered plug-in board
• Exploring complex relationships through experimentation
• Universal applications
• Robust components
• High degree of transparency
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Lucas-Nülle
System Overview
Needs-oriented Training Systems
Training on Real Components: CarTrain
CarTrain combines multimedial teaching material with real motor
vehicle components. System complexity is made far more accessible and hence understandable to the student using didactically
modified graphic interface design combined with optimized component configuration.
Your benefits
• Practice-oriented training using original components
• Measurements using workshop tester
• Fault simulation with up to 50 different faults
• Interactive learning software
• Real and simulation mode
• 3-D animations of individual components
• OBD readout function using CAN-Bus interface
• Tests and system comprehension questions
• Integrated instrumentation
• Freely-programmable control unit
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Lucas-Nülle
Kraftfahrzeugtechnik
Simulation and/or real mode assists in solidifying knowledge
and understanding for the overall system. Switchover can be
carried out during operation.
Using the OBD II terminal you can connect any OBD II-capable
diagnostics tester and read out important data needed for trouble shooting.
Deploys expert systems, determines data and updates it using
control unit software, perform resets to default settings on
motor vehicle systems.
Didactically designed interactive training software shows
how to design and operate sensors, actuators and subsystems of
the direct fuel injection system MED with turbo charger.
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Lucas-Nülle
Multimedia Learning Environment
LabSoft as System-based Training/Administration Software
LabSoft
LabSoft is the user interface for all automotive courses and constitutes an open experimentation platform that permits access to
all laboratory media:
• Navigation window with tree structure for display and direct
selection of all course components
• Experiment procedure including documentation
• Evaluation and storage of the measurement results
• Built-in fault simulator
• Virtual instruments perform real-time measurements
- Voltmeter, ammeter
- Storage oscilloscope
- Function generators
LabSoft Classroom Manager
The LabSoft Classroom Manager is comprehensive administration software for all LabSoft courses. The Classroom Manager
consists of various program elements:
LabSoft Reporter:
Monitor learning progress and generate statistics
LabSoft Editor:
Create and edit your own courses and tests
LabSoft Manager:
Manage user data and courses in LabSoft
LabSoft TestCreator:
Create test problems and exams
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Lucas-Nülle
Kraftfahrzeugtechnik
LabSoft in the Network
LabSoft supports both local installation on the user’s computer
as well as installation on a central server that permits access
via intranet or internet. To facilitate integration into Learning
Management Systems the developers of LabSoft incorporated
international standards.
UniTrain-I
LabSoft
CarTrain
Panel System
Manuals
In addition to in-depth descriptions the manuals cover
everything from commissioning the respective training system
to project examples and also include numerous exercises and
experiments.
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Lucas-Nülle
The Entire Program at a Glance
Solutions for Vocational Training and Education in Automotive Engineering
Electricity/Electronics
UniTrain-I
Basics of Electrical Engineering ...........................................
Basics of Electronics and Digital Technology........................
Three-phase Generator.......................................................
Pulse-width Modulated Signals...........................................
Alternative Drives
22
23
24
25
Panel System
Generator with Multifunction Controller ............................ 26
Generator with Hybrid Controller ....................................... 27
CarTrain
Electromobility ................................................................... 56
UniTrain-I
Hybrid Drive in Motor Vehicles ...........................................
DC/AC Conversion .............................................................
Fuel Cells ...........................................................................
Photovoltaics .....................................................................
58
59
60
61
Sensors and Actuators
UniTrain-I
Sensors and Actuators in the Motor Vehicle ....................... 32
Compact System
Sensor Technology in Engine Management ........................ 33
Motor Vehicle Lighting
Panel System
Main Lights ........................................................................
Auxiliary Lights ...................................................................
Trailer Lights.......................................................................
Static Cornering Light ........................................................
CAN-Bus Extension ............................................................
Onboard Power Supply Expansion ......................................
39
40
41
42
42
43
Chassis and Driving Safety
Comfort Systems
Panel System
Alarm System ..................................................................... 48
Compact System
GPS Navigation .................................................................. 48
Air-conditioning System ..................................................... 49
UniTrain-I
Auto Repair Shop Communication ..................................... 50
Comfort Systems ............................................................... 51
Compact System
Electromechanical Parking Brake ........................................ 96
Electromechanical Power Steering ...................................... 97
SRS Airbag ......................................................................... 99
ABS and ASR ................................................................... 101
UniTrain-I
Airbag ............................................................................... 98
ABS/ASR and ESP ............................................................. 100
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Lucas-Nülle
Networked Systems
Practical Training Lab
UniTrain-I
CAN Bus .......................................................................... 106
LIN Bus ............................................................................ 108
Fibre Optic Waveguides .................................................... 109
FlexRay ............................................................................ 110
Compact System
Exhaust Gas Analysis and EOBD Data Readout ................
Tire-Fitting Machine ........................................................
Balancing Machine ..........................................................
Axle Measurement ..........................................................
Hydraulic Lifting Platform ................................................
Air-conditioning Service Unit ...........................................
Motor Vehicle Tool Trolley ...............................................
Panel System
CAN Lighting Technology ................................................. 107
CAN Comfort Technology ................................................ 107
112
112
113
113
114
115
115
Compact System
Dashboard Training Model/Stand ..................................... 111
Engine Management
CarTrain
Motronic 2.8 ...................................................................... 68
Direct Fuel Injection ........................................................... 70
Common Rail ..................................................................... 72
UniTrain-I
Ignition Systems ................................................................. 78
Common Rail ..................................................................... 79
Compact System
Common Rail .....................................................................
Electronic Diesel Control ....................................................
Student/Teacher Measurement Stations ..............................
Functional Engine and Cutaway Model ..............................
Chip Tuning .......................................................................
Auto-Diagnosis Trainer Software ........................................
80
81
74
76
82
83
Motor Vehicle Diagnostics
Panel System
OBD-II ............................................................................... 88
Diagnostics Equipment
CAN/LIN Monitor ..............................................................
High-voltage instrumentation ............................................
Snap-on MODIS ................................................................
Snap-on SOLUS PRO .........................................................
Snap-on VERUS .................................................................
89
89
90
91
91
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Lucas-Nülle
Electricity/Electronics
DC and AC Technology in the Motor Vehicle............................. 22
Electronics and Digital Technology in the Motor Vehicle............ 23
Three-phase Alternator/Generator............................................. 24
Pulse-width Modulated Signals (PWM)...................................... 25
Three-phase Generator with Multifunction Controller............... 26
Three-phase Generator with Hybrid Controller.......................... 27
Electricity/Electronics
Kraftfahrzeugtechnik
Electricity/Electronics
Basic Practice-oriented Know-how
For years now electrical and electronic applications have been
playing an ever more important role in the motor vehicle. For
that reason it is essential for trainees to become familiar with
the most important fundamentals of automotive electrical
engineering from the outset. This is the prerequisite to
understanding the complex interactions taking place in the
vehicle. It is no accident that 80 training hours are planned for
20
this topic in the initial training year. Our training systems for
electronics and electrical engineering have been fine-tuned
specifically for everyday applications found on the job.
Supported by a host of examples, explanations, lessons and
practical exercises, the trainee acquires the background
know-how and develops the necessary skills.
Kraftfahrzeugtechnik
Electricity/Electronics
Analogue Technology
Digital Technology
In electrical engineering, an analogue system is one where physical quantities continuously vary in value and time. The LN case
system imparts the related fundamentals in a practical manner.
This topic deals with the processing of discrete-value and
discrete-time numerical sequences as well as digital signals.
Our basic courses are made up of typical automotive examples
and exercises intended to provide the most practical training
possible.
Training Systems
Our training systems cover the most important topics. Students
and trainees acquire the basics of electrical engineering and
electronics, become familiar with semiconductor components
and learn about basic and applied electronic circuits and basic
and applied digital circuits.
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Lucas-Nülle
Electricity/Electronics
Electricity/Electronics
DC and AC Technology in the Motor Vehicle
The growing importance of electrical and electronic components in the motor vehicle makes the hands-on training
approach to basic electronic circuits an absolute necessity. Our
UniTrain-I course on DC and AC technology in the vehicle enable
students to acquire this know-how through independent self-
learning. They come to grips with such terms as current, voltage
and resistance, train in how to operate measuring instruments
and conduct experiments using Ohm’s and Kirchhoff’s laws. All
of the required measuring instruments are already built into the
UniTrain-I’s multimedia training environment.
Conducting Measurements
with the Computer
Training contents
• Basic concepts of current, voltage and resistance
• Handling power sources and measuring instruments
• Usage of circuit diagrams for the analysis of electrical components
• Putting to use accident prevention regulations pertaining to work with electrical current
• Measurements on series and parallel circuits, voltage dividers and mixed circuits
• Evaluation of measurement findings using comparative tables
• Recording characteristics of variable resistors (LDR, NTC, PTC, VDR)
• Trouble 22
shooting
UniTrain-I course SO4204-7A
Lucas-Nülle
Electricity/Electronics
Electronics and Digital Technology in the Motor Vehicle
Knowledge of the characteristics and functionality of electronic
components forms the basis for understanding and analysing
such components and their circuits in motor vehicles. Course
topics include diode characteristics, basic transistor circuits,
determination of valve- and rectifier-action of a diode and circuit
design.
Training contents
• Open- and closed-loop control operations in motor vehicle components
• Component classification according to hydraulic, pneumatic or electrical/electronic systems
• Recording diode characteristics
• Setting the operating point on the basic transistor circuit
• Understanding and using gain, emitter and collector circuits
• Design of basic logic circuitry
• Becoming familiar with Boolean functions and laws
• Experimenting with static and dynamic switching response
• Design of counter circuitry
UniTrain-I course SO4204-7B
Lucas-Nülle
23
Electricity/Electronics
Electricity/Electronics
Three-phase Alternator/Generator
Virtually all modern motor vehicles are equipped with a threephase generator to produce the required electrical energy.
With the UniTrain-I course the trainees gain insight into the
generator’s basic functions and learn how to control it. They also
plan and carry out diagnostics, maintenance and repair work on
the power supply and the starting systems.
Training contents
• Generator principle
• Basics of three-phase current
• Diode and rectifier circuits
• Functionality of an unregulated three-phase alternator/generator
• Discrete and integrated voltage controllers
• Regulated three-phase alternator/generator
• Fault diagnosis
• Compliance with accident prevention regulations
24
UniTrain-I course SO4204-7D
Lucas-Nülle
Electricity/Electronics
Pulse-width Modulated Signals (PWM)
Many actuator systems in motor vehicles require variable power
levels for the devices being controlled. Actuators which need to
assume intermediate values between the ON and OFF limits are
controlled by means of pulse-width modulated signals. With our
training system trainees document their measurement results,
signals and fault protocols and analyse, evaluate and present
their findings. This way they are able to isolate faults and
propose suitable strategies for fault rectification.
Training contents
• Principle of PWM
• Automotive PWM applications
• Adjusting the power of electrical loads with PWM
• Measuring a PWM signal’s characteristics: frequency, amplitude, mark-to-space ratio
• Pulse width, edges and signal shapes
• Control and operating-current circuits
• Diagnosis of PWM-controlled components
UniTrain-I course SO4204-7J
Lucas-Nülle
25
Electricity/Electronics
Electricity/Electronics
Three-phase Generator with Multifunction Controller
This training system is used to examine how energy is generated
in modern motor vehicles. Today‘s compact generators make
use of a monolithic controller. This kind of multifunction controller (MFC) has now largely replaced hybrid controllers. A progres-
sive sequence of experiments gradually introduces students to
the subject of power generation in automobiles.
Training contents
• Workshop orders and descriptions of faults form the basis of students’ plans for testing and
repairing automotive electrical and electronic systems
• Principle of three-phase generation and voltage regulation
• Understanding how a three-phase alternating voltage arises
• Properties of a multifunction controller
• Understanding rectification and protection using power Z-diodes
• Battery monitoring (sensing)
• Examining pre-excitation (PWM)
• Fault diagnosis in the system
26
ASA 6 equipment set
Lucas-Nülle
Electricity/Electronics
Three-phase Generator with Hybrid Controller
Our system enables the trainees to become familiar with the
function of the hybrid controller. Experiments are conducted and
observations made as to how the hybrid controller maintains
the generator voltage at a certain level, regardless of speed
and load. The role of the average excitation current is explored
as well as how changes are brought about in the magnetic
field and stator winding induction. The trainees thereby learn
independently and can monitor their knowledge in exercises and
tests.
Training contents
• Workshop orders and descriptions of faults form the basis of students’ plans for testing and repairing automotive electrical
and electronic systems
• Principle of three-phase generation and voltage regulation
• Understanding how a three-phase alternating voltage arises
• Properties of a hybrid controller
• Understanding the necessity of exciter diodes
• Investigating the exciter current
• Fault diagnosis in the system
ASA 7 equipment set
Lucas-Nülle
27
Sensors and Actuators
Sensors and Actuators in the Motor Vehicle.............................. 32
Sensor Technology in Engine Management............................... 33
Sensors and Actuators
Sensors and Actuators
Processes Involving Sensors and Actuators
Sensors are like the motor vehicle’s “sensory organs”. They are
used to monitor rpm, vehicle speed, acceleration, fuel
concentration and other input variables. Such signals have
become indispensable for many process control functions in
management systems, be it related to the engine, the chassis or
30
safety and comfort. The LN training systems have been
didactically designed and include typical automotive
components integrated into them to demonstrate the functions
and applications of sensors and actuators.
Sensors and Actuators
Maximum Learning Efficiency
Practical
The multimedia training platform ensures fast learning, even
during independent study phases. Since the virtual measuring
devices are versions of their real-life counterparts and have been
integrated into the work environment, the courses are fully selfcontained and complete.
For the most practical possible instruction, all sensors in our
training and educational systems have features found typically
on automotive components. The compact system’s exercise
stands are especially well suited for demonstrations.
Hands-on
Our training systems also cover the topics on sensors on the automobile body and chassis as well as sensors in engine management systems. This virtually covers all of the relevant areas of
study (areas 3, 4 and 7).
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Lucas-Nülle
Sensors and Actuators
Sensors and Actuators
Sensors in the Motor Vehicle
In modern motor vehicles more and more components are being
monitored and controlled electronically. Sensors have several
jobs to do, including the detecting of physical data and converting this information into electrical signals which can then be
processed by control units.
Trainees should be able to grasp how this process works and the
effects different sensor stimuli have on these signals. Our system
allows students and trainees to learn and analyse the most
essential aspects of this process.
Recording Characteristics
with the PC
Training contents
• Physical principles of sensors: induction, Hall effect, piezo effect
• Understanding the function of sensors involved in engine control
• Comprehending inductive and Hall speed sensors and their function
• Throttle valve position measurement: throttle valve switch and potentiometer
• Air-flow measurement with hot-wire and hot-film sensors
• Pressure measurement in intake manifold
• Detection of shock waves with the knock sensor
• Temperature measurement with NTC and PTC sensors
32
UniTrain-I course SO4204-7F
Lucas-Nülle
Sensors and Actuators
Sensor Technology in Engine Management
This training system from the “Compact” product family permits
hands-on experimentation and demonstrations using a variety of
engine-management and chassis sensors. The system’s practical
design makes for highly realistic training. The students perform
diagnostics and repair work in the area of engine management –
just the way it is required on the job.
Training contents
• Understand how typical sensors operate
• Conduct typical electrical measurements on various engine management sensors
• Develop skills in interpreting and using circuit diagrams
• Build up diagnostic skills
• Plan and implement typical diagnostic strategies
• Conduct typical electrical measurements on various chassis sensors
SO3230-3A equipment set
Lucas-Nülle
33
Motor Vehicle Lighting
Main Lights .............................................................................. 39
Auxiliary Lights ......................................................................... 40
Trailer Lights ............................................................................ 41
Static Cornering Light .............................................................. 42
CAN-Bus Extension .................................................................. 42
Onboard Power Supply Expansion ........................................... 43
Motor Vehicle Lighting
Motor Vehicle Lighting
From Metal Filament Lamps to Adaptive Headlight Systems
For some time now lighting systems have been developing into
highly complex systems in modern vehicles. This has placed
growing demands on instructors in the automotive field to meet
the huge challenge of making the topic more “hands-on” and
easier to understand in the classroom. With our lighting wall
36
panel you not only have theoretical knowledge combined with
practical skills but a versatile training system that can cover static
cornering lights and also headlight systems with headlamp range adjustment as well as auxiliary and trailer lighting.
Motor Vehicle Lighting
Active Safety Provided by Lighting Systems
Static Cornering Lights
Vehicle lighting components are among those contributing
to active safety. The networking of the electrical system includes
also the vehicle’s lighting components. Innovations integrated
into state-of-the-art headlight systems are explored and explained here in a clear and practical manner.
This feature involves control of the headlights via the indicator
unit, yaw rate and travelling speed so as to perfectly illuminate
the road ahead, even on curves. This ensures a high level of convenience and safety when cornering. The LN “Static cornering
lights” training system can be integrated as an expansion kit into
the existing lighting system.
Training Systems
Our training systems cover the topics such as main lighting and
static cornering lights too. Furthermore, system expansion is
possible at any time to include, for example, auxiliary and trailer
light systems.
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Lucas-Nülle
Motor Vehicle Lighting
Motor Vehicle Lighting
Auxiliary Lighting and Signalling Systems
Driving safety can be enhanced through the use of auxiliary
headlights and fog lamps. There are diverse means of controlling
such components. Furthermore, every vehicle must possess a
signalling system by law. Circuits of practical relevance provi-
ding various means of controlling components serve as a bridge
between theory and practice.
Training contents
• Fog lights with relay
• Fog lights system including rear fog light and 2 relays
• Halogen lights for enhanced road illumination
• Reversing lights
• 3rd brake light
• Interior lights
• Delayed switching of interior lights
• Horn unit
• Standard-tone/loud-tone horn unit with relay
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Lucas-Nülle
Motor Vehicle Lighting
ALC 1.1 Main Lighting Equipment Set
The main lighting system including all supplementary equipment
is comprised of original automotive components.
With this system you establish the foundation for an individually
expandable lighting panel wall. Combine other modules together
to provide clear and easy understanding of a highly complex
lighting system.
Training contents
• Become familiar with local road traffic regulations
• Learn to distinguish between control and load circuit
• Practice protecting circuits with fuses
• Learn to use electronic relays
• Investigate how the manual headlight range adjustment works
• Record measurement values and document faults
ALC 1.1 equipment set
Lucas-Nülle
39
Motor Vehicle Lighting
Motor Vehicle Lighting
ALC 1.2 Auxiliary Lighting Equipment Set
This system is used to cover the topics involving auxiliary headlights and signalling systems – the latter is obligatory in every vehicle and thus enjoys special consideration in training programs.
What is of interest here is that control of these components can
vary depending on the vehicle. For that reason, instructors can
only profit from a system that allows them to become familiar
with different versions of these right there in the classroom.
Training contents
• Become familiar with local road traffic regulations
• Learn to distinguish between control and load circuit
• Practice protecting circuits with fuses
• Learn to use electronic relays
• Investigate how the manual headlight range adjustment works
• Record measurement values and document faults
40
ALC 1.2 equipment set (supplementary set for ALC 1.1)
Lucas-Nülle
Motor Vehicle Lighting
ALC 1.3 Trailer Lighting Equipment Set
Once upon a time trailer lighting was simple to explain but
those days are over. Now the demands being made on teachers
have grown in step with the complexity of the electrical system
in question. In today’s classroom it is not just how the plug’s
7-pin or 13-pin socket assignment works but also how to
protect the towing vehicle from overloading and whether or not
the control functions on the trailer comply with legal
stipulations.
Training contents
• Installation and commissioning of auxiliary equipment and systems according to manufacturing specs
• Perform retrofitting of lighting systems on the motor vehicle and become familiar with local road regulations
• Become familiar with local road traffic regulations
• Distinguish between control and load circuits
• Protect circuitry with fuses
• Record measured values and perform trouble shooting
• Trailer socket and plug assignments
ALC 1.3 equipment set (supplementary set for ALC 1.1)
Lucas-Nülle
41
Motor Vehicle Lighting
Motor Vehicle Lighting
ALC 1.4 Static Cornering Light Equipment Set
This system helps instructors to impart know-how in all topics involving auxiliary headlights and signalling systems – the
latter being obligatory in every vehicle and thus enjoying special
consideration in training programs. What is of interest here is
that control of these components can differ depending on the
vehicle. For that reason instructors can only profit from a system
that allows them to become familiar with various versions of
these right there in the classroom.
Training contents
• Use of circuit diagrams
• How the yaw rate sensor works
• Combination of cornering light and low
beam headlight
• Retrofitting auxiliary systems
• Calibration of motor vehicle components
ALC 1.6 CAN-Bus Extension Equipment Set
Expand any of the existing automotive lighting displays by a
CAN-bus node that is diagnostics capable. This novel concept
permits operation in low-speed mode and, with just the push
of a button, in high-speed mode, too. As a result, even without
a CAN-bus drive you can explore the basics of the different
transmission speeds and the voltage levels associated with them.
With the fault simulator you only have to activate a switch to
feed various ISO standard fault codes onto the CAN bus.
Training contents
• Design of a steering column control unit
• Data transmission via a CAN bus
• Fault patterns on a high-speed CAN bus and on a lowspeed CAN bus
• Data protocol for low-speed CAN (class B), data protocol
for high-speed CAN (class C)
• Perform diagnostics on the CAN bus and analyse the Baud
rate
• Carry out short-circuit test of the power output stage
42
ALC 1.4 equipment set and ALC 1.6 (supplementary set for ALC 1.1)
Lucas-Nülle
Motor Vehicle Lighting
ALC 1.7 Onboard Power Supply Expansion
The motor vehicle’s onboard power supply is very complex. The
authorities are constantly stipulating new rules and regulations
involving this aspect in motor vehicles. This means that expansions and adaptations of the training material should permit the
training system to reflect existing legal requirements. Facilitating
the adaptation of onboard power supply systems to the latest
technologies is one of the hallmarks of a training system designed for practical applications.
Training contents
• Design a daytime running light controlled using PWM control
• Use incandescent lamp circuit in practical applications
• Assemble a circuit designed to unload the onboard power supply during start ignition
• Understand the design of relay circuits and be able to use them in practical application
• Comprehend starter connection and how the internal starter circuitry works
ALC 1.7 equipment set (supplementary set for ALC 1.1)
Lucas-Nülle
43
Comfort Systems
Alarm System and Immobilizer.................................................. 48
GPS Navigation......................................................................... 48
Air-conditioning and Climate Control ....................................... 49
Auto Shop Communications with RFID ..................................... 50
Comfort Systems and Keyless Entry .......................................... 51
Comfort Systems
Comfort Systems
Process Procedures with Sensors and Actuators
Comfort systems increase the general safety and comfort of
both drivers and passengers of motor vehicles. Among these
amenities are electronic seat adjustments, interior air-conditioning and the storage of individualized preferences. This area
includes an extremely broad range of technologies.
46
Whether it be RFID, CAN or MOST bus technology, the comfort
systems field is expanding continuously. Based on job orders and
fault descriptions students plan diagnostics of individual components, carry out testing on comfort systems and do repair work
on original motor vehicle parts.
Comfort Systems
Air-conditioning
Immobilizer and Alarm System
A person’s ability to perform and concentrate is heavily influenced by the temperature and condition of the surrounding air.
Consequently, all efforts must be made to supply the passenger
compartment with fresh, filtered air whose temperature can be
raised or lowered depending on the exterior temperature.
The training system introduces students to the design and
functionality of an alarm system including an immobilizer and
a remote control. The system demonstrates how vehicles can be
safeguarded in actual practice.
Training Systems
Our training systems cover such topics as air-conditioning systems, alarm systems and GPS navigation but also some of the
latest RFID technologies are didactically adapted on such subjects
as keyless entry and comfort data storage.
47
Lucas-Nülle
Comfort Systems
Comfort Systems
ALC 7 Alarm Systems and Immobilizers
The alarm system issues optical and acoustic signals in the
event of attempted intrusion. Arranged compactly on a panel
for training purposes, this fully functional alarm system permits
clear demonstrations of functionality. In this course students can
activate and deactivate the alarm system. The system can easily
and optimally be integrated into the existing lighting systems
and it is extremely well suited to accommodate the retrofitting
of auxiliary systems for teaching.
CO3216-3C
Alarm System and Immobilizer
Training contents
• Design type and operation of an alarm system with
­immobilizer
• Testing and adjusting alarm system function and immobilizer
• Programme the country-specific modifications of the alarm
system and test how the alarm system works with other
motor vehicle components
• Fault simulation
GPS Navigation
To simulate navigation, special software is used to put the GPS
system into simulation mode. This is absolutely essential to learn
how the system operates. For storage purposes the navigation
system is housed in a light and robust case to protect it from
damage. The students are instructed how to put an auxiliary system into operation. They also check whether system installation
is technically feasible and permitted for specific motor vehicles.
System contents
• Simulation mode for navigation routes
• Highway information display
• 3-D map display
• Integrated RDS-TMC receiver
• Traffic lane guidance system
• Operable via remote control and touchscreen
• Automatic route calculation
• Integrated gyroscope and speedometer
• Active route search function
• Switchable between DVD and navigation mode
• Real-time language guidance
• Includes a connection and switch for a reversing camera
48
ALC 7 and LM8231 equipment set
Lucas-Nülle
Comfort Systems
Air-conditioning and Climate Control
This training system permits practical experimentation and
demonstration with a “Climatronic” automotive air-conditioning
unit with climate control. The system’s very realistic design in
our compact system makes for equally realistic training. The fully
functional system also permits training of evacuation and filling
of the air-conditioning system.
Training contents
• Assemble and put into operation an air-conditioning unit
• Consider how air-conditioning systems add to the comfort
and safety features of a motor vehicle
• Deepen your understanding of refrigeration technology
• Perform independent trouble shooting, maintenance and
repairs on the air-conditioning system
• Learn how open- and closed-loop temperature control
works in the vehicle’s passenger compartment
• Investigate air-conditioning operation principles
• Elaboration of air-conditioning components promotes independent learning
• Learn how to handle refrigerants and to comply with regulations
SO3230-4A equipment set
Lucas-Nülle
49
Comfort Systems
Comfort Systems
Auto Shop Communications with RFID
Communication with customers and filling out customer job
orders form the basis for every single activity that follows. Information on motor vehicle data is obtained not only in talks with
the customer but also by technical means involving communication between the motor vehicle and the PC. RFID (radio-frequency identification) technology is used to access the motor vehicle
data contained in the motor vehicle’s key and read it out. This
course provides insight into this functionality and its applications
in the area of automotive engineering. The system comprising
reader and transponder is studied both in terms of power as
well as data transmission.
Training contents
• Planning and preparation of work processes
• RFID applications generally and specifically in the motor
vehicle
• Service job order
• Understanding the components required for data exchange
• Complete job order
• RFID transponder and antenna ranges
• The driver’s key as a communication tool
• Physical context and standards
• Communication with internal and external customers
• Reading data into the motor vehicle key
• Reading data out of the motor vehicle key
50
UniTrain-I course SO4204-7G
Lucas-Nülle
Comfort Systems
Comfort Systems and Keyless Entry
Comfort systems in the motor vehicle provide an essential,
overall boost to active safety. Drivers are reluctant to do without
a certain amount of driving comfort. New innovative operating
systems quickly penetrate the market and rapidly become the
standard. Training covers all the essentials of testing, diagnosing,
repairing and performing adjustments on comfort systems, safety
systems and door-locking systems all in accordance with
customer requirements and includes documenting the results.
With an excellent grasp of the system the applications are easier
to implement in practice.
Training contents
• Comfort settings in the motor vehicle
• Capacitive pushbutton
• Active safety
• Basics of antenna technology
• Door-locking system
• How central locking works with CAN bus and expansion to
keyless system
• Central locking
• Remote radio control
• Keyless access to vehicle
UniTrain-I course SO4204-6G
Lucas-Nülle
51
Alternative Drives
CarTrain Electromobility ........................................................... 56
Hybrid Drive in Motor Vehicles ................................................. 58
DC/AC Conversion ................................................................... 59
Fuel Cells ................................................................................. 60
Photovoltaics ........................................................................... 61
Alternative Drives
Alternative Drives
Hybrid Drives
These drives are revolutionizing the car industry and your
students need to keep pace with the latest developments and
technologies. Demonstrate in the classroom how less fuel consumption, lower emissions and maximum driving pleasure can
be realized with alternative drives. Sustainable, environmentally
54
friendly mobility is the trend for the future. Students and trainees should become familiar with this today so that they can
hold their own in the workplace of tomorrow. Our training system covers the entire area of alternative drives and subsystems.
Alternative Drives
Generator Operation
Regenerative Braking
Source: Bosch
Source: Bosch
In generator mode, the power output of the combustion engine
is higher than that needed for moving the vehicle. The excess
power is fed to the generator, where it is converted into electrical energy and stored.
In this mode, the vehicle is braked entirely or partly without the
service brake’s frictional torque, which is replaced by the braking
moment generated by the electric motor. In this process, the
vehicle’s kinetic energy is converted into electrical energy and
stored.
Training Systems
Our training systems cover not only these but additional topics
as well. The UniTrain-I system for hybrid drives serves to impart
the basics of alternative drives. Later, this acquired know-how is
supplemented using the CarTrain system covering electromobility.
As such the trainee becomes familiar with
photovoltaic and fuel cell functionality.
55
Lucas-Nülle
Alternative Drives
Alternative Drives
CarTrain Electromobility
When we think about the future of our planet the development
and production of vehicles equipped with hybrid drives is a
logical and necessary step. Lower emissions and less fuel
consumption are benchmarks for future generations of modern
automobiles. Such measures ensure that the fundamentals
necessary for life are sustained while quality of life improves.
Hybrid motor vehicles and electric cars are not just a future
consideration, but in fact the auto industry has already made
them available on the market. The only rational diagnostic
strategy available for these vehicles presupposes the necessary
system understanding.
Touchscreen Using Interactive
Operator Guidance
Training contents
• Use of HV systems in motor vehicles
• How electrical machines function
• Smart grid
- Inverters
• Vehicle to grid
- Switching possibilities of three-phase motors
• Drive concepts in HV vehicles
• Work safety
• Energy flows in HV systems
• Design of electrical machines
• Onboard power supply of HV vehicles
• Asynchronous machines
• Practical, hands-on procedures in the repair shop
• Synchronous machines
• Electromagnetic compatibility
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CO3221-6D equipment set
Lucas-Nülle
Alternative Drives
Your benefits
Interactive Course Software
•Structured course software
•3-D animations
•Animated energy flows
•Knowledge tests
•PC-based evaluations
•Integrated measurement software
•Job orders
Parameter Settings
•Adjustable driving modes
- Ascending gradient
- Level plane
- Descending gradient
•Speed
•Battery charge level
Drive Concepts
Interchangeable overlay masks for:
•Serial hybrid
•Serial hybrid with plug-in
•Parallel hybrid
•Parallel hybrid with plug-in
•Fuel-cell operated vehicle
•Purely electric vehicle
•7 drive configurations
Practical Work
•Circuit isolation
•Protect against reactivation
•Establish zero-voltage
•Operate original measuring instruments
•Integrated fault simulator
•Indication of fault codes in the HV system
•Handling HV systems
57
Lucas-Nülle
Alternative Drives
Alternative Drives
Hybrid Drive in Motor Vehicles
Hybrid drives are essentially meant to meet three objectives: save
fuel, reduce emissions, and increase torque/power. Different
hybrid concepts can be employed depending on the required
application. With our system trainees can learn on their own the
most important technical fundamentals of hybrid drives. Based
on job orders and fault descriptions students plan diagnostics
of individual components, carry out testing on systems and do
repair work on original motor vehicle parts. In the course of
measurements and experiments the students acquire practical
know-how for every day on the job and vocational training.
Training contents
• Benefits of hybrid systems
• Fundamentals of frequency converters
• Serial hybrid system
• Three-phase voltage supply
• Parallel hybrid system
• Measuring
• Combined hybrids
- DC voltage
• Design of electrical machines
- AC voltage
- Asynchronous machines
- Three-phase AC voltage
- Synchronous machines
• Investigation of energy and power flows
• Fundamentals of inverters
• Onboard power supply of hybrid vehicles
- Converters
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UniTrain-I course SO4204-6V
Lucas-Nülle
Alternative Drives
DC/AC Conversion
Electric energy is tapped at the car battery in the form of DC
voltage and is then applied as a DC current. However, in modern
electrical drives an AC voltage is needed with an approximate sinusoidal alternating current. In this course the generation of AC
voltage and currents is described and demonstrated in a simple
and graphic fashion.
The knowledge acquired in the theoretical section is then verified
empirically by means of experiment. All of the components needed for the experiment are arranged on a single printed circuit
board. In knowledge tests the student’s progress is checked and
thus the most important aspects of DC/AC conversion are effectively learned in the fastest possible time.
Training contents
• Ohm’s law
• PWM modulation
• Generation of half-wave sinusoidal current
• Generation of a negative voltage
• Alternating voltage and alternating current
• Magnetic fields permeating a coil
• The rotating electrical field
UniTrain-I course SO4204-6L
Lucas-Nülle
59
Alternative Drives
Alternative Drives
Fuel Cells
Motorized vehicles (cars, trucks) produce large quantities of CO2.
Despite considerable advancements, the internal combustion
engine still has very high CO2 emission levels. It is therefore no
surprise that engineers are seeking alternative drive concepts
here. In this training system students get to know and understand this fascinating technology. One interesting drive concept
involves the use of electrical drive motors in conjunction with a
fuel cell.
Training contents
• Fuel cell application in the motor vehicle
• Properties of fuel cells
• Function of a fuel cell
• Recording characteristics
• Design of a fuel cell
• Efficiency of a fuel cell
• Fundamentals of the chemical process
60
UniTrain-I course SO4204-6M
Lucas-Nülle
Alternative Drives
Photovoltaics
The term photovoltaics means a direct conversion of sunlight
into electrical energy by means of solar cells. The energy obtained in this manner can be supplied to ancillary consumers
to enhance driving comfort, e.g. to additionally cool a vehicle’s
interior in extremely bright sunshine. With our Unitrain-I Photovoltaics System students very quickly grasp the fundamentals of
this technology.
Training contents
• Use of a photovoltaic system on a motor vehicle
• Series-connected photovoltaic cells
• Design of a photovoltaic cell
• Parallel-connected photovoltaic cells
• Open-circuit voltage
• Direct operation
• Short-circuit current
• Storage operation
• V-I characteristic
• Power of a photovoltaic cell
UniTrain-I course SO4204-6N
Lucas-Nülle
61
Engine Management
CarTrain Motronic 2.8 .............................................................. 68
CarTrain Direct Fuel Injection .................................................... 70
CarTrain Common Rail ............................................................. 72
Student/Teacher Measurement Stations .................................... 74
Functional Engine and Cutaway Models ................................... 76
Ignition Systems ....................................................................... 78
Diesel Injection System Common Rail ....................................... 79
Common Rail ........................................................................... 80
Electronic Diesel Control (EDC) ................................................. 81
Connect®-Fire Chip Tuning ....................................................... 82
Auto-Diagnostics Trainer Software ........................................... 83
Engine Management
Engine Management
Networked Systems in the Engine Compartment
Increasingly complex engine management systems place growing
demands on trainees in the automotive field. Our modular
training systems provide students with step-by-step introductions
to how modern systems involved here operate. That trainees
frequently have problems following the material is due less to
the material itself and more often to the way it is presented.
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Thanks to practical hands-on elements our system assists the
instructor by motivating each and every student regardless of the
degree of difficulty or the student’s knowledge level. The
following pages provide an introduction to our training systems.
Engine Management
Fuel Mixture Preparation
Chip Tuning
Source: Bosch
Lucas-Nülle’s training systems provide students with a fully comprehensive introduction to the subject of fuel mixture preparation. The steps needed for optimizing fuel mixtures, registering
and processing operational data, and outputting the data as
actuator signals can be directly observed and understood here.
All modern vehicles have an engine controlled by a central
processor. This so-called engine control unit, or ECU, also
monitors operating states. The Connect®-FIRE training system
permits chip tuning on a single-cylinder, four-stroke engine.
Training Systems
Besides the topics mentioned above, our training systems also
cover ignition systems, engine management systems for sparkignition and diesel engines, functional engines and chip tuning.
All of these systems feature a close linkage between the practical
and the theoretical.
65
Lucas-Nülle
Engine Management
Engine Management
From the Theoretical to the Practical – CarTrain as a Universal Solution
Modern combustion engines are not only facing constant
mechanical optimization but also continuous and increasing
complexity of their engine management systems. Laws and
regulations are in constant flux also in an effort to minimize
environmental pollution. But how we deal with new testing procedures and work rules does not alter the fact that the biggest
challenge to doing perfect maintenance, repair and diagnostics
work is still overall “system understanding”. For that reason
the link between theory and practice is even more important
in the training phase. Knowing and recalling the location and
function of the sensors and actuators is of particular importance
and comes from hands-on work. Using original motor vehicle
components in the training system facilitates the learning and
understanding of this fascinating technology.
Multimedia Training Course
The world of multimedia-based learning has opened up whole
new horizons to both students as well as teachers and instructors. Self-learning is possible thanks to the text guiding method.
Technical relationships and context which are difficult to explain
with a two-dimensional image are converted into animations
and clips which provide detailed insight into the technology and
its complexity. Many of the test pages directly show learning
progress of the student(s) and can be evaluated individually or
as a group by the teacher at the press of a button.
Integrated Measuring Instruments
There is a whole series of integrated measuring instruments
which bring together hardware and multimedia training courses.
This is how measurement results and oscilloscope traces can be
integrated directly into the documentation using drag and drop
or other applications utilized. This saves time and reduces the
number of errors. Clarity and accessibility remain guaranteed,
and the written instructions on how to operate the measuring
instruments are also included in the multimedia training course.
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Lucas-Nülle
Engine Management
Your benefits
Simulation and/or Real Modus
The sensors can be switched between simulation modus and
real modus. In simulation modus rotary switches can be used to
make random settings so that students can learn how these have
repercussions on engine management. In real modus the actual
ambient variables are put into the equation.
OBD-II Function
This course demonstrates how to read out emission data with
the help of the onboard diagnosis OBD II or an OBD-II capable
terminal, interpret the data and use the results as a basis for
eliminating systemic faults. Many more OBD-II functions are also
at your disposal including read out of actual values and error
memory deleting.
Fully Functional Original Components
Using fully functional original components you can learn how the
various engine management systems operate. Here one important
focus is on trouble shooting in connection with realistic sensor
and actuator variables.
Programming Engine Characteristics Map
Using expert systems to identify, check and upgrade control unit
software: these are all topics involving expert systems and engine
characteristics programming. The CarTrain engine management
systems are equipped with a freely programmable control unit
in which you can read out, process and optimize existing characteristic maps. As such this system is perfectly suitable for an
introduction into the fascinating topics of chip tuning, control unit
programming and remote diagnostics.
Fault Simulation
All CarTrain systems come equipped with a built-in fault simulator.
The complexity of the faults ranges from simple line interruptions
to fault-to-earth or fault-to-positive battery terminal, and even
includes contact resistances, defective components and control
unit faults.
67
Lucas-Nülle
Engine Management
Engine Management
CarTrain Motronic 2.8
The motronic system unites in one control unit the engine
management’s entire electronics (air-fuel mixture and ignition).
Motronic 2.8 is a multi-point injection system in which each cylinder has its own injection valve. The actuators contained in this
training system are controlled as a function of corresponding
sensor signals. Different driving conditions can be reproduced
and analysed. All sensors and actuators of the engine management system are original, fully functional components.
Training contents
• Understand how the engine management system works
• Function and operation of the relevant control loops
• Design and operating principles of the sensors and actuators
• Interpretation and application of circuit diagrams
• Conducting hands-on measurements on engine management components
• Fault memory read out
• Measuring and testing electrical, electronic, hydraulic, mechanical and pneumatic variables
• Engine management system settings
• Expert systems and remote diagnostics
68
CO3221-6F equipment set
Lucas-Nülle
Engine Management
Your benefits
Interactive Course Software
•Structured course software
•3-D animations
•Knowledge tests
•PC-based question evaluation
•Integrated measurement software
•Job orders
•Fault enabling via software
Operating Unit
Switch individual sensors between real and simulation mode
•RPM
•Coolant temperature
•Intake air temperature
•Knock sensor
•Air mass
•Lambda sensor
Original Components
•Crankshaft sensor
•Camshaft sensor
•Throttle valve potentiometer
•Knock-sensor
•Air-mass meter
•Voltage jump sensor
•Single-spark ignition coil
•Idle actuator and much more
Hands-on Work
•Record characteristics
•Compare actual and desired values
•Read out fault memory
•OBD function
•Trouble shooting
•Fault elimination and repair
•Connect up original workshop tester
69
Lucas-Nülle
Engine Management
Engine Management
CarTrain Direct Fuel Injection
The MED direct fuel injection system with turbo charger
combines the entire engine control system (air-fuel mixture and
ignition) in one single control unit. The MED direct fuel injection
with turbo charger is a multi-point injection system meaning that
each cylinder is equipped with its own injection valve.
The training system is designed to perform actuator control as a
function of corresponding sensor signals. Different driving
conditions can be reproduced and understood. The sensors and
actuators used in the engine management system are original,
fully-operational components.
Training contents
• Understand how the engine management system works
• Grasp how the control loops in the system operate
• Learn about the design and function of sensors and actuators
• Learn how to interpret and use circuit diagrams
• Conduct practical, hands-on measurements on the engine management components
• Read out fault memory
• Measure and test electrical, electronic, mechanical, hydraulic and pneumatic variables
• Adjust engine management system parameters
• Learn to use expert systems and remote diagnostics
70
CO3221-6G equipment set
Lucas-Nülle
Engine Management
Your benefits
Characteristic Map Programming
•Reading out characteristics map
•Processing characteristics
•Adjusting setpoint values
•Control unit flashing
•Display of all parameters
•How to use programming software
Workshop Work
•Read out vehicle data
•Read out fault memory
•Repair cables
•How to use circuit diagrams
Original Components
•Accelerator pedal sensor
•Broadband Lambda sensor
•Voltage jump sensor
•Rail pressure sensor
•Manifold pressure sensor
•Rail pressure control valve
•High-pressure injection valve
•E-gas throttle valve and more
Practical Hands-on Work
•Record characteristics
•Compare actual and setpoint values
•Read out fault memory
•OBD function
•Fault finding
•Trouble shooting
•Connect up original workshop tester
71
Lucas-Nülle
Engine Management
Engine Management
CarTrain Common Rail
The common rail engine management system combines the
entire engine control electronics into a single control unit. The
training system is designed to perform actuator control as a
function of the corresponding sensor signals. This makes it pos-
sible to reproduce and understand different driving conditions.
The sensors and actuators used in the engine management
system are genuine, fully-operational components.
Training contents
• Understand how the engine management system works
• Grasp how the control loops in the system operate
• Learn about the design and function of sensors and actuators
• Learn how to interpret and use circuit diagrams
• Conduct practical, hands-on measurements on the engine management components
• Read out fault memory
• Measure and test electrical, electronic, mechanical, hydraulic and pneumatic variables
• Adjust engine management system parameters
• Learn to use expert systems and remote diagnostics
72
CO3221-6E equipment set
Lucas-Nülle
Engine Management
Your benefits
OBD-II Terminal
•Read out motor vehicle data
•Delete error memory
•Display actual values
•Compatible to all OBD-II diagnostic equipment
•CAN-bus data protocol
Realistic Workshop Activities
•Read out motor vehicle data
•Delete error memory
•Repair cables
•Handle circuit diagrams
Original Components
•Accelerator pedal sensor
•Air mass meter
•Rail pressure sensor
•Rail pressure controller
•Crankshaft sensor
•Camshaft sensor
•Engine temperature sensor
•Air temperature sensor and more
Hands-on Work
•Recording characteristics
•Comparing actual and setpoint values
•Read out error memory
•OBD function
•Trouble shooting
•Fault correction
•Connecting original workshop tester
73
Lucas-Nülle
Engine Management
Engine Management
Student/Teacher Measurement Stations
Extremely flexible, closely networked and safe student/teacher
measurement stations are just what teachers and instructors
are looking for. That’s why Lucas-Nülle has developed a system
which permits the trainee and the trainer to receive the same
signals. The signals are transmitted by a training system like CarTrain or by a real vehicle. This is because the new system can be
connected to any electronic device, in other words from other
Lucas-Nülle training systems outside the automotive area. The
new student/teacher measurement stations from Lucas-Nülle
Training System with Signal Generation
Teacher Measurement Station Interface
Student Measurement Stations
74
also permit high-voltage signals to be sent from the teacher’s
workstations. The signal is automatically converted and output
to the student workstations at a lower voltage. But the signal
curve depicted graphically is shown precisely as it would be for
the high-voltage case. This way the students learn to cope with
typical aspects of high-voltage work without being exposed to
the danger.
Engine Management
Student/Teacher Measurement Station
A gateway has been integrated into the teacher’s measurement
station. This enables the feed-in of different CAN-bus signals.
This exam-relevant subject makes for efficient instruction
particularly in combination with the new student/teacher
measurement stations. A terminating resistor is connected to
the last interface of each system for automatic bus determination. An additional and very essential advantage for the teacher is
the fact that any malfunctions or interruptions occurring at the
student measurement stations are indicated with the actual
workstation number. This allows the teacher or instructor to
immediately detect and respond to the interruption. This
minimizes any unnecessary breaks in the instruction and thus
boosts learning success.
Your benefits
• Universal deployment in all types of vocational training classes
• Transmission of analogue and digital signals
• Signal inputs up to +/- 500 V / signal outputs up to +/- 15 V
• Precise signal transmission
• Easy assembly and disassembly
• Digital display for diagnosing line interruptions
• Low disturbance rate
• Simple lab network using Ethernet cables
CO3221-7A and CO3221-7B equipment set
Lucas-Nülle
75
Engine Management
Engine Management
Functional Engine and Cut-away Models
Naturally, as a full-service outfitter of technical training centres and educational institutions, we also offer pure functional
engines with up-to-date technology. You can decide for yourself
whether you need only a functional engine or a complete motor
vehicle that has been modified for training purposes. All of the
manufactured systems comply with high safety standards so
that there is no exposure to moving parts. Protective covers are
also included to safeguard hot components. All systems can be
retrofitted with a fault-simulation circuit whose signals can be
tapped using break-out boxes. Furthermore these systems are
supplied with original workshop documentation.
Contact us for further information!
Functional Engines
Standard commercial diagnostic testers can be used to read out
the functional engine’s error memory via the OBD terminal in
order to perform typical automotive diagnoses. As in real life,
all signals can be tapped from the cable harness or the plug
connectors. A switch can be used to easily simulate typical
electrical faults on the engine. In addition to short set-up times
and solid training units the trainee also achieves more than just
collecting abstract knowledge – real hands-on work skills are
developed. Many different instructional situations can be produced using this system. Accordingly the trainee can work through
a customer order during a project in which the motor vehicle is
prepared for servicing and the prescribed check-up and testing
conditions are set up. You identify the motor vehicle using
technical information systems and record the manufacturer and
customer data. Finally the system is checked for errors during
trouble shooting.
Examples of a cut-away model. Even
more models and information available
from your sales partner!
Example of a functional engine. Additional models and information can be
obtained from your sales partner!
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Lucas-Nülle
Engine Management
Cut-away Models
In order to organise training as practically as possible the LN
cut-away motor vehicle has been specially modified didactically
for training purposes. All important components have been configured accessibly in order to permit direct measurement access
to sensor and actuator signals. To simulate typical workshop
situations, malfunctions can be fed into the system by means of
a hidden fault switching box.
Your benefits
• Practice-oriented training with original vehicles and components
• All components are fully functional
• Interpreting technical documentation
• Simulating malfunctions
• Conducting direct measurements on the motor vehicle/engine without assembly or disassembly
• Conducting measurements on all systems with the engine running
• Examination of electrical and mechanical components
77
Lucas-Nülle
Engine Management
Engine Management
Ignition Systems
To ignite the air-fuel mixture, combustion engines have always
needed an ignition system. Nowadays such ignition systems have
become extremely complex and precise in order to comply with
emission standards while at the same time enabling modern
combustion engines to unleash their tremendous power. With
our training system the trainees come to grips with these topics
early on and can use the UniTrain-I system to learn on their own
and at their own speed how the ignition system is designed,
what can go wrong and how this can be identified. Trainees also
learn to carry out diagnostics and maintenance in the area of
engine management.
Training contents
• Observe how the ignition spark is generated
• Learn about ignition timing (mechanical and map-based)
• Conventional ignition system and dual-spark ignition systems are introduced
• Transistorized ignition systems with Hall and inductive sensors
• Become acquainted with the electronic ignition system
• Learn how to record and evaluate ignition oscillographs
• Find out the basics of static and rotary high-voltage distribution
78
UniTrain-I course SO4204-7C
Lucas-Nülle
Engine Management
Common Rail Diesel Injection System
What goes into making a diesel engine run “smoothly“? How
can engines be designed to lower exhaust gas emissions? The
fact that everything is just a question of the injection system
makes this field all the more exciting. This topic is made easier
to comprehend using our training system which empowers the
trainee to learn about injection pressures, processes and air-fuel
quantities in a self-controlled learning process. Covering the
entire spectrum of systems available on the market the trainees
are able to switch between the various injector types and thus
gain an overview of the entire topic.
Piezo technology with up to
seven injection cycles
Training contents
• Requirements to be met by diesel injection systems
• Introduction to various designs
• Design and functionality of a common rail system
• Fault localization on a common rail system
• Injection characteristics of common rail systems and
piezo injectors (with up to seven injection cycles)
• Investigation of the fuel system and differentiation between low- and high-pressure circuits
• Understand the process of electrical tests of injectors
• Examination of a common rail system’s hydraulics
UniTrain-I course SO4204-6X
Lucas-Nülle
79
Engine Management
Engine Management
Common Rail
Common rail is an injection system for self-igniting combustion
engines. Map-controlled injectors can be operated and diagnosed here just like on a real engine. As such, trainees at
vocational schools or industrial training centres have access to
a realistic work environment which they need to develop solid
skills and expertise. Using our comprehensive system the students learn on original components. They consider the ramifications
of malfunctions on the engine’s subsystems, the combustion
process and gas emission composition.
Training contents
• Combustion process
• Open-loop and closed-loop control
• Pollutant emissions
• Engine management subsystems
• Reduction in pollutant emissions
• Assembly groups and systems for fuel mixture preparation
in diesel engines
• Block circuit diagrams, circuit diagrams, functional diagrams
and graphs
• Adaptive systems
• Signal, material and energy flows
• Interfaces to other systems
• Diagnostic, testing and measuring equipment
• Fuels
• Test and measurement procedures
• Sensors and actuators
80
SO3230-1F equipment set
Lucas-Nülle
Engine Management
Electronic Diesel Control (EDC)
Electronic diesel control is an electronic management system for
diesel engines. With our system the trainee can become familiar
with and understand EDC and all the open- and closed-loop
control functions in one electronic engine control unit as well as
the large number of sensors and actuators that are connected
to it. Furthermore the students learn to analyse malfunctions
and their impact on the engine’s sub-systems, the combustion
process and the composition of the gas emissions.
Training contents
• Combustion process
• Engine management sub-systems
• Pollutant emissions
• Reduction in pollutant emissions
• Assembly groups and systems for fuel mixture preparation
in diesel engines
• Block diagrams, circuit diagrams, function diagrams, graphs
• Adaptive systems
• Signal, material and energy flows
• Interfaces to other systems
• Diagnostic, testing and measuring equipment
• Fuels
• Test and measuring methods
• Sensors and actuators
• Open-loop and closed-loop control
SO3230-1E equipment set
Lucas-Nülle
81
Engine Management
Engine Management
Connect®-FIRE Chip Tuning
Software-controlled Performance Optimization at the Engine Test Stand
Connect®-FIRE is the compliment to the globally unique
interactive multimedia-based Connect® engine management
system. The Connect®-FIRE’s extraordinary feature is its compact
injection engine, designed in miniature format including an
electronically controlled load, control unit, interface and
intelligent teach- and software. Here original components are
merged with a didactically designed, multimedia-based training
platform to create a training system that gets any student
passionate about cars.
Characteristic Maps and Chip Tuning
Performance Optimization on the Engine Test Stand
Training contents
• Trainees conduct measurements on different engine management components
• Observe engine response to changes in timing settings
• Edit and optimize characteristic maps for idling, ignition and injection
• Record performance and torque characteristics
• Carry out performance and torque optimization (chip tuning)
• Ultimately trainees also investigate emission characteristics
82
AMM 91 equipment set
Lucas-Nülle
Engine Management
Auto Diagnosis Trainer Software
Lucas-Nülle’s new automobile diagnosis trainer (ADT) software is
meant for students to develop and consolidate strategies for
successful automotive diagnosis and trouble shooting using a
training program before moving on to real vehicles.
Thus the new software constitutes the ideal preparation for
work on real systems. By completing this preliminary step the
trainees are able to handle work on the vehicle more confidently, more effectively and thus mistake-free.
A Complete Engine Management
System Mathematically Reproduced
Simulation of up to 170 Malfunctions
Training contents
• Diagnosis and maintenance in the area of engine management
• Developing diagnostic strategies
• Planning fault localization and repair measures
• Documenting, monitoring and assessing implemented measures
• Working with block, circuit and function diagrams
• Working with measurement devices and diagnostic tools
SO2500-1A equipment set
Lucas-Nülle
83
Vehicle Diagnostics
Onboard Diagnosis II ................................................................ 88
CAN /LIN Monitor ..................................................................... 89
High-voltage Instrumentation ................................................... 89
Snap-on MODIS ...................................................................... 90
Snap-on SOLUS PRO ................................................................ 91
Snap-on VERUS ........................................................................ 91
Vehicle Diagnostics
Vehicle Diagnostics
Developing Diagnostics Strategies
Teaching systematic vehicle diagnostics including the associated
trouble shooting methods in such a way that the trainees not
only follow the procedures but can also implement them confidently on their own is the true challenge for any trainer. It is also
important to consider manufacturer-specific diagnostic concepts
in this process. Maintenance strategies are planned on the basis
86
of customer information, visual checks and the results of independent diagnosis. Trainees use our systems on vehicle diagnostics to assimilate this multi-facetted approach while working on
modular courses and at experiment stands that empower them
to carry out project work on their own.
Vehicle Diagnostics
Onboard-Diagnosis II
Engine Tester
This is used by students to perform diagnoses in the area of
engine management. Students identify the engine management
system with the help of electronic information systems and
vehicle-specific documents, and perform system analyses. A
standard interface provides access to the engine control unit.
This is how students learn the entire, realistic process of onboard diagnostics as it is carried out on the job everyday in the
automotive workshops and businesses.
The engine tester is an indispensable aid for diagnosis, maintenance and repair of all important automotive systems. It can be
used to read vehicle-specific data, errors and parameters out of
the various control units. For that reason it constitutes one of
those key tools that trainees need to master very early on, like
the engine tester which also has to be operated confidently.
Training Systems
Our products include training systems for such topics as on
board diagnosis II and trouble shooting methods. Furthermore,
we offer supplementary systems which can be used to carry out
instruction in the petrol and diesel diagnostics.
87
Lucas-Nülle
Vehicle Diagnostics
Vehicle Diagnostics
Onboard Diagnosis II
This course demonstrates how to read out emission data
with the help of the onboard diagnosis unit (OBD II or EOBD),
interpret the data and use the results as a basis for eliminating
systemic faults. Students have the possibility to adjust various
parameters on their own to see how these settings affect the
tester. They also have the opportunity to tap the CAN transmission signal to display it on the oscilloscope.
Training contents
• The system permits the diagnosis of emission-relevant systems
• Systematic development of trouble shooting and diagnostic strategies
• Working with test devices
• Planning fault localization and repair measures
• Evaluating and documenting test results
88
CO3216-1Z equipment set
Lucas-Nülle
Vehicle Diagnostics
CAN/LIN Monitor
The CAN/LIN monitor allows bus protocols on a CAN bus, LIN bus
or any serial bus to be recorded and investigated.
Your benefits
• Visual display of bus protocol structure
• Option for displaying in binary or hexadecimal code format
• Recording of bus packets
• Transmission of bus packets
• Suitable for student experiments and demonstrations
• Simple to put into operation
• Displays
- identifier
- data length
- period
• User-configurable graphic interface
High-voltage Instrumentation
This flexible measurement system permits rapid, safe and simple
diagnosis of high-voltage motor vehicles. Here emphasis is on
maximum protection for personal safety and the motor vehicle.
Your benefits
• Flexible system for simple integration into the testing and
diagnostics platform
• Adaptable interface to log test procedure and record
results
• Multimeter up to 1000 V
• HV insulation resistance measurement
- Test voltage up to 1000 V
- Voltage according to SAE J1766
• Simple operation
- Even includes HV protective clothing
• Calibration certificate in accordance with DIN EN ISO 9002
• Self-testing
• Test current max. 1 mA
• Automatic disabling of test voltage in the event of a fault
or physical contact
SO2000-2A and LM8258 equipment set
Lucas-Nülle
89
Vehicle Diagnostics
Vehicle Diagnostics
Snap-on MODIS
This is the latest generation of diagnostics systems with multiple
applications. It is based on a modular diagnostic concept and
includes very high manufacturer coverage and enormous testing
depth. Before you have to replace the control unit this device is
capable of localizing sporadically occurring faults and malfunc-
tions and provides a wide range of testing possibilities. In
addition to a four-channel oscilloscope the Modis offers an
additional VGA output. Consequently this diagnostics unit can
be connected directly to a projector making it an unbeatable
highlight for any type of instruction.
Your Benefits
• Lightweight device, easy to handle on the job, simple to operate
• No subscription obligation, no disabling of device after 2 years
• Fully functional, high-performance diagnostics tool: fast lab and ignition scope, error code scanner, trouble shooting module
and multimeter all in one device
• All cable sets are included in the scope of delivery
• Rapid diagnosis: quick vehicle selection, short communication set-up with control unit
• Very high manufacturer coverage and data depth of individual vehicle makes
• Stores measurement value sequences/data film; simplifies discovery and analysis of sporadic faults
90
LM8255 equipment set
Lucas-Nülle
Vehicle Diagnostics
Snap-on SOLUS PRO
Using the Solus Pro you can read out all of the vehicle data of
every single manufacturer. The graphic display simplifies making
comparisons between different parameters.
Your benefits
• Large 6.2“ display
• Rapid communication setup
• Window CE operating system
• Freeze frame function for rapid and easy diagnosis
• Graphic display of all data
• USB connection to PC
• CAN-bus support
• Adapter cable for
- 11 OBD-I plugs
- OBD-II adapter
• Error code display in plain language
Snap-on VERUS
VERUS is the first fully integrated, hand-held diagnostics tool
with customer/vehicle recording function, scanner, Snap-on
trouble shooting, component test meter, 4-channel lab scope,
Fast-Track® reference database and optional ShopKey repair
information as well as reprogramming feature using J2534
pass-thru interface.
Your benefits
• The bright colour display with 26.4 cm (10.4 inch) diagonal screen measurement and a resolution of 1024 x
768 facilitates the read out of curves, waveforms, circuit
diagrams, web pages and much more besides
• Time-saving navigation via touchscreen and key shortcuts
for each application
• Comprehensive screen display – real Window Multitasking for multiple applications
• Intuitive Windows XP operating system – rapid startup
and operation thanks to embedded technology
LM8261 and LM8260 equipment set
Lucas-Nülle
91
Chassis and Driving Safety
Electromechanical Parking Brake .............................................. 96
Electromechanical Power Steering ............................................ 97
Airbag, Seat-belt Tensioner and Crash Behaviour ...................... 98
SRS Airbag and Seat-belt Tensioner .......................................... 99
ABS, ASR and ESP .................................................................. 100
Brake Power Control with ABS and ASR ................................. 101
Chassis and Driving Safety
Chassis and Driving Safety
Active and Passive Safety
The sensors and actuators of the systems involved here perform
important functions for active and passive safety, comfort as well
as engine management in motor vehicles. Driving safety and impact protection features are especially significant to the safety of
a vehicle’s occupants. Work on such safety components requires
94
sound qualifications acquired through first-rate training and education systems. Students are introduced to the complex subjects
by a combination of e-learning courses and real-life compact
systems, and are able to apply acquired skills on true replicas of
original components.
Chassis and Driving Safety
ABS
Airbag
ABS measures a wheel’s circumferential speed. During braking,
the wheel’s slip is calculated automatically and the brake pressure regulated accordingly. This prevents the wheel from blocking. Our true replica of an original ABS system allows students
to examine these functions and perform related measurements.
The airbag training environment from our family of panel systems allows practical experiments and demonstrations using an
SRS airbag and seat-belt tensioner. This UniTrain-I airbag course
includes a steering wheel with a fully functional, re-usable
airbag.
Training Systems
Our training systems cover such topics as airbag and belt tensioner, ABS and ASR, chassis technology, steering systems and
transmission technology. All systems feature original components
and thus have a very stimulating effect on students and trainees
alike.
95
Lucas-Nülle
Chassis and Driving Safety
Chassis and Driving Safety
Electromechanical Parking Brake with Auto-hold Function
An electromechanical parking brake replaces the conventional
handbrake with a simple switch on the dashboard so that there
is no need for a handbrake lever. On uphill starts, sensors
determine how steep the slope is. If the driver stops the vehicle,
the brake engages automatically until the car is started again.
This new auto-hold function is being integrated into more and
more vehicles and in the future will gain in significance. In our
system we have depicted the modern electromechanical parking
brake in such a way that it is easily understood and can be
experimentally tested by trainees and students.
Training contents
• How rear-wheel brake actuators work
• Sensors and actuators in an electromechanical
parking brake
• How an electromechanical parking brake works
• Parking brake function
• Dynamic pull-away assistant
• Dynamic emergency brake function
• Auto-hold function
• Understanding how brake boosters and hydraulic
brakes work
• Interpretation and use of technical documentation
• Experimental investigation of the various functions for
improved understanding
• Assembly, configuration and testing of mechanical
components
• Design and function of disc brakes
• Gauging of brake discs
96
CO3221-9A equipment set
Lucas-Nülle
Chassis and Driving Safety
Electromechanical Power Steering
Electromechanical power steering has many advantages over
hydraulic steering. It assists the driver not just in purely physical
terms, but also intelligently by responding only when the driver
explicitly requests it. Steering assistance is provided as a function
of vehicle speed as well as steering moment and angle. With
this fully functional cutaway model the trainees quickly learn just
how electromechanical power steering works. They also have
the opportunity to conduct CAN measurements directly on the
steering mechanism.
Training contents
• Design of an electromechanical power steering
• Function of the individual assembly groups
• Steering geometry
• Inverter control
• CAN-bus control
• Vehicle speed sensor
• Steering angle sensor
• Steering moment sensor
CO3221-9B equipment set
Lucas-Nülle
97
Chassis and Driving Safety
Chassis and Driving Safety
Airbag, Belt Tensioner and Crash Response
Active safety systems like airbags and seat-belt tensioners have
been standard features in all vehicle classes for years. Regular
inspections of these features are needed to ensure that they
operate properly. For that reason this has become a routine
part of everyday auto garage work. Trainees learn the necessary
know-how and trouble shooting strategies using this system as
realistically as possible.
Original Airbag
Optional: SO3219-1P
Training contents
• Active and passive safety in motor vehicles
• Operating principles of airbags and seat-belt tensioners
• Safety switch and ignition cap
• Operating principle of pressure and acceleration sensors
• Measurement of acceleration
• Typical crash situations
• Trigger times and sequences
• Fault management for airbag systems
• Trouble shooting
98
UniTrain-I course SO4204-6Z
Lucas-Nülle
Chassis and Driving Safety
SRS Airbag and Belt Tensioner
This training environment from our family of “Compact” systems
allows the trainee to analyse corresponding systems in practical
experimentation and demonstrations using an SRS airbag and
seat-belt tensioner and includes testing exercises. The system’s
very realistic design, including the use of manufacturer-specific
diagnostic concepts, makes for equally realistic training.
Training contents
• Understanding the functionality of an SRS system
• Understanding the operating principles of pyrotechnic actuators (airbag and seat-belt tensioner)
• Identifying the effects of typical faults on SRS systems
• Conducting various electrical measurements
• Interpreting and employing technical documentation
• Building up diagnostic skills
• Planning and implementing typical diagnostic strategies
SO3230-2D equipment set
Lucas-Nülle
99
Chassis and Driving Safety
Chassis and Driving Safety
ABS/ASR/ESP
Brake systems of modern motor vehicles are becoming increasingly complex. Electronic aids such as ABS, ASR and ESP are now
standard features in such systems. They are designed to keep the
vehicle stable with physical limits and thus help assist in protec-
ting the driver. Each individual system is mutually dependent and
in part uses the same sensor signals. With this training system
the trainee becomes familiar with and understands how the
various systems function and interact.
Training contents
• Basic physics of driving
• ASR function and design
• Understeering
- Controlling situations
• Oversteering
• ESP function and design
• Function and design of sensors
- Operating principle
• ABS function and design
- What is slip?
- ABS control loop
100
UniTrain-I course SO4204-6W
Lucas-Nülle
Chassis and Driving Safety
Brake Power Control with ABS and ASR
This training system permits practical experimentation and demonstrations by means of an electronically controlled ABS / ASR
brake system (Bosch 5.3). All important electrical signals can
be tapped centrally via 4-mm sockets. As such, trainees have
the opportunity to practice realistic work and thus eventually
transfer the acquired know-how to the real job. This system also
permits read-outs using OBD diagnostics tools.
Training contents
• Understanding the functionality of typical ABS and ASR brake systems
• Understanding the functionality of brake boosters and hydraulic brakes
• Identifying the effects of typical malfunctions on ABS and ASR brake systems
• Conducting various electrical measurements
• Interpreting and employing technical documentation
• Building up diagnostic skills
• Planning and implementing typical diagnostic strategies
SO3230-2C equipment set
Lucas-Nülle
101
Networked Systems
CAN Bus ................................................................................ 106
CAN Lighting Technology ...................................................... 107
CAN Comfort Technology ..................................................... 107
LIN Bus .................................................................................. 108
Fibre Optic Waveguides .......................................................... 109
FlexRay .................................................................................. 110
CAN- and LIN-Bus Dashboard Training Stand/Model ............... 111
Networked Systems
Networked Systems
Active and Passive Safety
The onboard network of a new motor vehicle resembles the IT
network of a medium-sized company, in which 70 to 90 control
units are connected by various data buses over which data is
exchanged at an intense rate. Today over two-thirds of all
innovations in the automobile are software-based. That makes it
all the more essential to integrate and to teach this know-how
104
and the necessary practical expertise that goes with it. The LN
training systems have content that covers all of the standard bus
systems. The combination of original components, experiments
and self-directed learning leads to the acquisition of solid
know-how and skills.
Networked Systems
Optical Data Bus Systems
Networks
Large quantities of data can be transmitted with the help of
light waves. The UniTrain-I course on optical waveguides
contains practical examples demonstrating how to handle such
waveguides.
An automobile can be divided into various data communication
zones, each one being assigned particular duties which place
corresponding demands on the network. For this reason, the
automobile is organized into a number of sub-networks. The
various possibilities of doing this are clearly demonstrated in our
courses on bus systems.
Training Systems
With our training systems teachers and trainers can provide
instruction of the typical automotive bus systems like CAN bus,
LIN bus, MOST bus and FlexRay. The trainees not only become
familiar with them but experiment on them independently and
thus learn to comprehend their complex technical relationships.
105
Lucas-Nülle
Networked Systems
Networked Systems
CAN Bus
Modern motor vehicles incorporate numerous electronic control
units which communicate with each other continually via digital
bus systems. Widely used for this purpose in passenger cars as
well as commercial vehicles are CAN buses, especially when it
comes to comfort, engine management and diagnostic applica-
tions. This training system thus conveys important information in
a very realistic manner. Trainees can use this system to carry out
diagnostics and repair work on networked electronic systems
inside the motor vehicle.
From the Theory to the Control of
Original Motor Vehicle
Training contents
• Rationale for using bus systems in motor vehicles
• Design of a CAN message’s frame
• Topology and components of a CAN-bus system in
a motor vehicle
• Analysing CAN messages with a CAN monitor and
­oscilloscope
• Differences between low-speed and high-speed CAN
• Editing and sending CAN messages via a PC
• Electrical properties of a CAN bus
• Trouble shooting
• Data rate, identifier, addressing and arbitration
(low-speed and high-speed CAN)
106
UniTrain-I course SO4204-7K
Lucas-Nülle
Networked Systems
Training Projects Involving a CAN Bus
CAN Lighting Technology,
­Programming and Diagnostics
Your benefits
The ”Lighting technology“ training project supplements
the CAN-bus course with an additional control unit. The
”Lighting technology“ interface makes it possible to control any conventional lighting system. Such systems can be
controlled via the switches and buttons on the UniTrain-I
cards forming part of the ”CAN bus“ course.
• Universally deployable
• Baud rate can be set arbitrarily
• Trouble shooting carried out on real components
• Freely programmable data
CAN Comfort Technology
­Programming and Diagnostics
Your benefits
The ”Car door“ training project integrates an original car
door into the experimentation system. This allows the
door’s essential functions (e.g. electric window winder
and electrically adjustable external mirror) to be controlled
by means of real CAN messages. The resultant data traffic
on the CAN bus can be analysed using the applications
forming part of the LabSoft course.
CAN-Bus-controlled Motor Vehicle Lighting and Door equipment set
Lucas-Nülle
107
Networked Systems
Networked Systems
LIN Bus
In addition to the CAN bus, the somewhat simpler LIN bus is
also used. This bus is employed mainly for comfort systems
which are not crucial to safety. With this training system stu-
dents examine the bus protocol and learn to perform systematic
trouble shooting.
Training contents
• Development of bus systems in motor vehicles
• Message frame structure
• Topology and components of a LIN-bus system
• Analysis of LIN messages
• Electrical properties of a LIN bus
• Editing and sending LIN messages
• Addressing of a LIN bus
• Trouble shooting
• Master/slave principle
• Measurement tests of data fields
108
UniTrain-I course SO4204-7E
Lucas-Nülle
Networked Systems
Fibre Optic Waveguides
At present, optical bus systems are used mainly to achieve high
data transmission rates in luxury automobiles. However, optical
buses are likely to find broader use in view of the increase in data
volumes that generally require processing in automobiles. For
that reason fibre optics is an important topic for today’s trainees
and will be met with more and more frequently on the job. Our
training system has been designed so that trainees can distinguish between open and closed loops and classify them in accordance with their electronic systems.
Training contents
• Data networks in motor vehicles
• Optical bus systems in motor vehicles
• Rationale for using optical waveguides in automotive
applications
• Fundamentals of ray optics (refraction, reflection)
• Fundamentals of the MOST bus
• Data transmission and optical measurements on optical
waveguides
• MOST protocol and control units
• Attenuation by optical waveguides
• Ring breakage diagnosis
• Design of optical waveguides in motor vehicles
UniTrain-I course SO4204-7H
Lucas-Nülle
109
Networked Systems
Networked Systems
FlexRay
In recent years the amount of electronics present in the automobile has increased at a steady rate. This also involves an ever
more complex network of sensors, actuators or control units
as well as entertainment and navigation systems. FlexRay is the
communication system when it comes to x-by-wire systems. The
system requirements are primarily focused on data.
Training contents
• Becoming familiar with and distinguishing between the
various bus systems used in motor vehicles
• Identification of typical errors and their verification using
measurement techniques
• How the FlexRay bus system work
• Learning about the function and operation of the steer-bywire technology
• Component communication using the FlexRay bus
• Data exchange in a FlexRay network
• Developing deeper understanding through practical applications of the FlexRay protocol
110
UniTrain-I course SO4204-6Y
Lucas-Nülle
Networked Systems
Dashboard Training Model Incorporating CAN and LIN Buses
This model comprises an original dashboard (VW Golf V) with an
instrument panel, driver’s and front passenger’s airbags, as well
as the entire lighting system, including instrument lighting. The
model includes a flexible fault simulation circuit. Also present are
diagnostic plugs for measurements on control units, e.g. for the
airbag or illumination.
Training contents
• CAN bus for light control/central locking/comfort
window winder
• Horn operation
• LIN bus for wiper and mirror control
• Clear demonstration of instrument lighting
• Fan, ventilation, circulating-air mode
• Circuit comprising headlights and range adjustment
mechanism
• Headlight settings
• Indicator light settings
• Hazard warning system
SO3240-1D equipment set
Lucas-Nülle
111
Practical Automotive ­
Workshop Lab
Exhaust Gas Analysis and EOBD Data Readout ...................... 116
Tire-Fitting Machine ............................................................... 116
Balancing Machine ................................................................. 117
Axle Measurement ................................................................. 117
Two-column Hydraulic Lifting Platform ................................... 118
Four-column Hydraulic Lifting Platform ................................... 118
Fully Automatic Air-conditioning Service Unit.......................... 119
Vehicle Tool Trolley ................................................................. 119
Practical Automotive Workshop Lab
Practical Automotive Workshop Lab
Complete Solution – a Practical Lab for Assembly, Dismantling
and Diagnosis of Vehicles and Automotive Assembly Groups
Diagnosis and maintenance of engine
management systems
Dismantling, repair and installation of
automotive assembly groups and systems
114
Lucas-Nülle
Practical Automotive Workshop Lab
Documentation and communication,
database systems
Maintenance of chassis systems
Maintenance of comfort systems
115
Lucas-Nülle
Practical Automotive Workshop Lab
Practical Automotive Workshop Lab
Exhaust Gas Analysis and EOBD Data Readout
Analyses of exhaust gases from combustion engines provide
information on the composition of such gases and depend on a
variety of factors, including the type of fuel, combustion process
and engine model.
Your benefits
• Emission tests of vehicles with a spark-ignition or diesel
engine and of EOBD vehicles with a spark-ignition or
diesel engine
• Large LCD display for indicating results
• Integrated vehicle database
• Storage of customer-specific data
• Interface for export to the ”AU-Plus“ module
• Infrared remote control
• Rollers for device mobility
Tyre-Fitting Machine
The tyre-fitting machine covers all workshop requirements for
modern tyre-fitting technology. Stable, safe and fast, the machine complies with international specifications.
Your benefits
• Ability to accommodate wide range of tyres
• Pneumatic locking of the fitting arm and release of the
fitting head
• Pneumatic, backward-tilting mounting column
• Powerful drive motor
• Compliant with UL/CE international specifications
116
LM8218 and LM8219 equipment set
Lucas-Nülle
Practical Automotive Workshop Lab
Balancing Machine
Increasingly complex chassis components on modern motor
vehicles entail increasingly precise wheel-balancing techniques.
Your benefits
• Three programs for aluminium rims
• Program for hiding weights behind rim spokes
• Manual entry of wheel data
• Simple switchover between grams and ounces
• Quick wheel locking and release
• High dependability to the nearest gram
• Universal tightening nut
Axle Measurement
Axle measurement and adjustment are required if the vehicle
drifts left or right instead of travelling straight ahead.
Your benefits
• Standard measurement, quick measurement and supplementary measurement
• Program for low-chassis vehicles
• Customer-specific vehicle database
• Robust measuring heads
• System protection against water spray
• Standard batteries and standard PC
• Self-centering clamp holder
LM8220 and LM8234 equipment set
Lucas-Nülle
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Practical Automotive Workshop Lab
Practical Automotive Workshop Lab
Two-Column Hydraulic Lifting Platform
The lifting platform is an essential feature at any automotive
workshop.
Your benefits
• Two-column hydraulic lifting platform with a floor-level
cable receptacle
• Electromagnetic release of the safety mechanism
• Manufactured according to international standards, e.g.
CE standard
• Two hydraulic cylinders each
• Chain guard for protecting operators
• Electromechanical height limitation
• Levelling of both lifting carriages via cable control
Four-Column Hydraulic Lifting Platform
This lifting platform is especially suited to axle measurement. All
necessary components such as the axle jack, sliding plates and
rotary disc for axle measurement are included.
Your benefits
• Variable distance between the rails
• Axle jack, sliding plates and rotary disk for axle
measurement included
• Manufactured according to international standards, e.g.
CE standard
• Two hydraulic cylinders each
• Chain guard for protecting operators
• Electromechanical height limitation
• Leveling of both lifting carriages via cable control
118
LM8237 and LM8238 equipment set
Lucas-Nülle
Practical Automotive Workshop Lab
Fully Automatic Air-Conditioning Service Unit
This easily operable air-conditioning service unit incorporates
several functions such as leakage detection, recycling, cleaning,
evacuation and replenishment.
Your benefits
• Recycling of residual refrigerant
• Cleaning of refrigerant through drying, filtration and
separation of oil as well as liquids according to the SAE
standard
• Refilling of the air-conditioning system
• Checks of the cooling system for leakages
• Replacement of old oil with a fresh batch to lengthen
the compressor’s life cycle
• Emptying of hoses and system parts to ensure that exactly the required quantity of refrigerant is refilled
• Measurement of the filling quantity
Trolley with 64-part Tool Kit
This specially composed vehicle tool kit contains all the tools necessary for carrying out professional repairs. Made of high-quality
alloys, the entire assortment of tools complies with DIN as well as
ANSI standards.
Your benefits
• Professional, high-quality tool kit
• Compliant with DIN and ANSI standards
• Contains all tools needed for professional repairs
• Tools are stored in a practical, hard-shell case
LM8239 and LM8242 equipment set
Lucas-Nülle
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Kraftfahrzeugtechnik
p. 18
p. 19
pp 20, 22, 23
p. 21
pp. 28, 29
pp. 34, 35, 36, 37, 38,
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p. 44
p. 45
p. 46
Fundamentals of electronic/digital
technology
Three-phase generator
Pulse-width modulated signals
Engine management sensors
Motor vehicle lighting
Alarm system
GPS
Air-conditioning
Repair shop communication RFID
Training Topics
Fundamentals of DC and AC technology
Training Topics
1 Maintenance/care of vehicles and automotive systems
2
Dismantling, repair and installation of automotive assembly
groups and systems
3 Testing/maintenance of electrical and electronic systems
4
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Testing/maintenance of open-loop and closed-loop
control systems
5 Testing/maintenance of power supply and starting systems
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6 Testing/maintenance of engine mechanics
7 Diagnosis and maintenance of engine management systems
x
8 Servicing and maintenance of exhaust systems
9 Maintenance of power transmission systems
10 Maintenance of chassis and brake systems
11 Retrofitting and commissioning of auxiliary systems
12 Testing and maintenance of networked systems
13
Diagnosis and maintenance of body, comfort and
safety systems
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14 Servicing and maintenance for statutory inspections
120
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p. 55
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pp. 68, 75, 76
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pp. 92, 96, 97
p. 93
pp. 94, 95
pp. 102, 103, 107
pp. 104, 107
p. 105
p. 106
Comfort systems and keyless entry
Hybrid drives
DC/AC conversion
Fuel cells
Photovoltaics
Motronic 2.8
Indirect fuel injection
Common rail
Ignition systems
Electronic diesel control
Chip tuning
Engine diagnosis
Onboard diagnosis II
Brake systems
Steering systems
Airbag
CAN Bus
LIN Bus
Fibre optic waveguides
FlexRay
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Lucas-Nülle
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121
Essential Product Benefits
… Ensure Long-term Customer Satisfaction
Bernd Klein, instructor at the Nikolaus-August-Otto vocational school, regularly uses Lucas-Nülle’s automotive training
systems in his lessons.
“
Having worked with Lucas-Nülle for many years now, we are satisfied with their self-learning concepts. Our trainees are especially keen
to use software-based training systems.
Also very popular with instructors here are the robust lighting and signalling units.
In general, Lucas-Nülle’s training systems make instruction at vocational schools much more practical.
”
122
Lucas-Nülle
Kraftfahrzeugtechnik
The Whole is Greater
than the Sum of its Parts
Individual consultation with Lucas-Nülle
Do you require comprehensive advice or a firm offer?
Then you can contact us using any of the following means:
Tel.:
+49 2273 567-0
Fax:
+49 2273 567-39
Lucas-Nülle is a byword for custom occupational training courses in all of the following areas:
Electrical Wiring
Electropneumatics and Hydraulics
Electrical Power Supply Technology
Measurement and Instrumentation
Technology
Renewable Energies
Refrigeration and Air-conditioning
­Technology
Power Electronics, Electrical Machines,
Drive Technology
Microcomputers
Fundamentals of Electrical Engineering
and Electronics
Automation
Communications Technology
Automotive Technology
Control Technology
Laboratory Systems
Ask us for detailed information using any of the given methods of contact.
Our employees will be happy to advise you.
Further information on our products can be found at the following web addresses:
www.lucas-nuelle.com
Lucas-Nülle
Ref. No.: P 5145
Automotive Engineering
05/12-3GB (Printed in Germany)
Subject to technical alterations.
Lucas-Nülle
Lehr- und Meßgeräte GmbH
Siemensstraße 2 · D-50170 Kerpen-Sindorf
Telephone: +49 2273 567-0 · Fax: +49 2273 567-69
www.lucas-nuelle.com · export@lucas-nuelle.com